Z-World XP8900 Technical Information

California AHMCT Research Center University of California at Davis California Department of Transportation DEPLOYMENT SUPPORT OF AHMCT MACHINES 1

Deployment Support x Copyright 2011, AHMCT Research Center, UC Davis

Deployment Support xi Disclaimer / Disclosure The research reported herein was performed as part of the Advanced Highway Maintenance and Construction

Deployment Support xii Copyright 2011, AHMCT Research Center, UC Davis

1 Chapter1 Introduction The Deployment Support Task Order has allowed for a wide range of support to numerous AHMCT projects from July 01, 1999 to J

2 Copyright 2011, AHMCT Research Center, UC Davis

3 Chapter 2 Supported Projects 2.1 Introduction The support of machines is extensive during the field deployment phase of the project. However, ad

4 actual roadway for the purpose of retrieving debris. The following plan of action was devised. Plan of Action • Install and implement a new hydr

5 develop the anti-collision radar system. When traveling around corners, trees can appear as a possible collision; however, these are merely false

6 Therefore, a battery charging isolation system was added including two additional heavy density batteries. The additional batteries allowed more e

7 With each field test, complete training in the safe operation of the machine was provided. Additionally, operators and their supervisors were prov

Copyright 2011, AHMCT Research Center, UC Davis

Copyright 2011, AHMCT Research Center, UC Davis

DRV Final Evaluation Report 1 Appendix A Copyright 2011, AHMCT Research Center, UC Davis

DRV Final Evaluation Report 2 Copyright 2011, AHMCT Research Center, UC Davis

DRV Final Evaluation Report 3 Debris Removal Vehicle (DRV) AHMCT Evaluation Report Aaron Raley Deployment Support October, 2001 Unive

DRV Final Evaluation Report 4 Introduction The field operational testing and evaluation phase of the Debris Removal Vehicle (DRV) project has produce

DRV Final Evaluation Report 5 Plan of Action • Install and implement a new hydraulic and electronic control system that exhibits reliable and contr

DRV Final Evaluation Report 6 operator constrained in a standard vehicle cab and presents ergonomic design issues. Important areas to investigate are

DRV Final Evaluation Report 7 reported complaints by any operators regarding the use of a joystick relating to comfort or effort. The efficiency of t

DRV Final Evaluation Report 8 arises when the work zone is close to the vehicle as found when retrieving debris next to a sound wall or on a narrow sh

DRV Final Evaluation Report 9 handled with anticipation of the DRV being used to retrieve it, that the machine could be more efficient than a manual o

Technical Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient’s Catalog No. 4. Title and Subtitle Deployment Support For AHM

DRV Final Evaluation Report 10 looking out the side window. This was accomplished with the combination joystick pushbutton control. There were no re

DRV Final Evaluation Report 11 implement with a standardized interface allows for the adaptation to debris localized to a single region not considered

A1 AHMCT Release for Field Operational Testing and Evaluation We, the undersigned, have observed a demonstration of the Debris Removal Vehicle and w

A3 The AHMCT Research Center, in conjunction with the Caltrans Equipment Service Center, has rebuilt the Debris Removal Vehicle (DRV). The following

A3 tanks were having problems equalizing due to plumbing complications. A single tank was used in place of the dual tanks and new plumbing installed

Copyright 2011, AHMCT Research Center, UC Davis

Summary of Repairs Conducted on the Debris Removal Vehicle (DRV) During Field Testing for the Period 1/01/01 – 5/31/02 January 2001 Report Auto du

imposing an excessive force on the position sensor. The force is great enough to loosen the lock nut on the position sensor and allow the sensor to

The long arm axle bolt rotated on the set screw. In addition, there was a problem with the backup battery in the controller. All motion profiles a

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Appendix B Copyright 2011, AHMCT Research Center, UC Davis

Deployment Support iv Copyright 2011, AHMCT Research Center, UC Davis

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Copyright 2011, AHMCT Research Center, UC Davis

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) The Debris Removal Vehicle Operator’s Manual and Technical Reference

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Copyright 2011, AHMCT Research Center, UC Davis

Machine Operation 23 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) TABLE OF CONTENTS 1 INTRODUCTION Theory of Operation.

Machine Operation 24 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) 1: Theory Of Operation The Caltrans/AHMCT Debris Removal

Machine Operation 25 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) 2.1.5 System Power On Place the power switch on the opera

Machine Operation 26 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) 2.2 System Operation 2.2.1 Joystick The majority of mot

Machine Operation 27 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) compactor cycle, the compactor indicator light will blink

Machine Operation 28 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Boom Up/Down Raises or lower the boom Turntable CW/CCW R

Machine Operation 29 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) (blinking) Gate Up System is executing an automatic motio

Deployment Support v Abstract The purpose of work was to provide support to machines developed by the AHMCT Center and deployed into the Caltrans wor

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Appendix A Main Controller Copyright 2011, AHMCT Research Center, UC Da

Appendix A: Main Controller 31 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) A.1 Introduction The entire DRV is controlled by

Appendix A: Main Controller 32 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) A.1.1 Keypad On the embedded computer is located

Appendix A: Main Controller 33 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) pos P gain: 0.0...100.0 0.80 velo P gain:

Appendix A: Main Controller 34 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) velo D gain: 0.0...100.0 0.150 Max CCW pos

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Appendix B Trouble Shooting Copyright 2011, AHMCT Research Center, UC

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) B.1 Introduction The DRV utilizes an industrial controller. The controller ha

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) state the logic gate input, which is high impedance and considered infinite fo

Appendix B: Touble Shooting 38 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Never use a test light to check an output. Une

Appendix B: Touble Shooting 39 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) For fuse locations on the fuse block, reference

Deployment Support vi Copyright 2011, AHMCT Research Center, UC Davis

Appendix B: Touble Shooting 40 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) 1: "System Ready" on LCD 2: Arm respon

Appendix B: Touble Shooting 41 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Figure B.3: Fuse locations Copyright 2011, AH

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Appendix C Wiring Diagrams Copyright 2011, AHMCT Research Center, UC D

Appendix C: Wiring Diagrams 43 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Copyright 2011, AHMCT Research Center, UC Davi

Appendix C: Wiring Diagrams 44 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Cable Routing POSITION_4Z-CONTROLLERCONTROLCON

Appendix C: Wiring Diagrams 45 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Copyright 2011, AHMCT Research Center, UC Davis

Appendix C: Wiring Diagrams 46 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Copyright 2011, AHMCT Research Center, UC Davis

Appendix C: Wiring Diagrams 47 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Copyright 2011, AHMCT Research Center, UC Davis

Appendix C: Wiring Diagrams 48 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Copyright 2011, AHMCT Research Center, UC Davis

Appendix C: Wiring Diagrams 49 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Copyright 2011, AHMCT Research Center, UC Davis

Deployment Support vii Executive Summary The AHMCT Research Center has been developing and field testing demonstrable prototypes for many years inclu

Appendix C: Wiring Diagrams 50 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Copyright 2011, AHMCT Research Center, UC Davis

Appendix C: Wiring Diagrams 51 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) CONSOLE SWITCHES 8459 22 AWG PIN: COLOR: F

Appendix C: Wiring Diagrams 52 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) INDICATOR LIGHTS 8624 16 AWG PIN: COLO

Appendix C: Wiring Diagrams 53 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) DUMP BODY SENSORS 9457 20 AWG PIN COLOR

Appendix C: Wiring Diagrams 54 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) DUMP BODY VALVES 8624 16 AWG PIN COLOR

Appendix C: Wiring Diagrams 55 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) JOYSTICKS 83569 22 AWG PIN: COLOR: FUNCT

Appendix C: Wiring Diagrams 56 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) ROBOT POSITION 83569 22 AWG PIN COLOR F

Appendix C: Wiring Diagrams 57 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) ROBOT PWM VALVES 83719 16AWG PIN COLOR

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Appendix D Hydraulic Schematics Copyright 2011, AHMCT Research Center,

Appendix D: Hydraulic Schematics 59 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) this page intentionally left blank (inf

Deployment Support viii Copyright 2011, AHMCT Research Center, UC Davis

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Appendix E Cable Specifications Copyright 2011, AHMCT Research Center

Appendix E: Cable Specifications 61 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Cable Specification Belden # Cond. AWG

DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Appendix F Electrical Parts List Copyright 2011, AHMCT Research Cente

Appendix F: Electrical Parts List 63 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Parts List ZWorld Part # ZWo

Appendix F: Electrical Parts List 64 DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) Appendix G Hydraulic Parts List

Appendix G: Hydraulic Parts List DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000) this page intentionally left blank (inform

Appendix C Copyright 2011, AHMCT Research Center, UC Davis

Changing Timer Pre-sets on the LCSM II The PLC must be turned on to change the pre-set timer values and the updated values only exist while the sys

Appendix DCopyright 2011, AHMCT Research Center, UC Davis

Automated Cone Machine Safe Operation 1.1 Overview The ACM is an automated piece of equipment that places and retrieves traffic cones. It allows

Deployment Support ix Table of Contents Abstract ...

There is a primary funnel located on each of the corners of the vehicle. Operators should verify that these areas are clear before energizing the s

1.3 Equipment Checkout In order to reduce the opportunity of damage and/or malfunction, a thorough check out of the machine should be done prior to

5. Set the ‘PICK/DROP’ switch to the center position 6. Turn on the computer 7. Turn on the System Power 8. Select machine side ‘LEFT’ or ‘RIGHT

1.4.4 Ending Operation When the operation is completed, move the ‘DROP/PICK’ switch into the center position. Set the ‘LEFT/RIGHT’ switch to the ce

Appendix ECopyright 2011, AHMCT Research Center, UC Davis

Copyright 2011, AHMCT Research Center, UC Davis

Copyright 2011, AHMCT Research Center, UC Davis

Machine Limitations 1. The ACM was designed to work with 28“ cones that have had the raised rubber feet removed. Using any other configuration co